Packaging, shipping and display system

ABSTRACT

A packaging, shipping and display system having a one piece molded tray and a corrugated cover for a stack of products such as lawn and garden spreaders. The tray includes wheel wells, a rest stand well and four latching tabs. The tabs are pliable strips and may be easily pulled out to form a convex shape or pushed in to form a concave shape. The cover includes latching tab receiving cutouts. To latch the cover to the tray, the tabs are pulled out. To unlatch, the tabs are pushed in. The cover and the tray stay connected when the tabs are pulled out because an abutment occurs between the tabs and borders of the cover tab receiving cutouts. The package of a tray, latched cover and a stack of products may be easily moved by gripping hand cutouts in the cover.

BACKGROUND OF THE INVENTION CROSS REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not applicable.

1. Field of the Invention

The present invention relates to a packaging and display system and more particularly to an efficient, easy to use and inexpensive packaging system that may also be used for display purposes.

2. Description of the Related Art

Certain products such as lawn and garden spreaders are typically shipped and displayed in a stacked configuration as shown in U.S. Pat. No. 5,489,023 to Paul Havlovitz. The Havlovitz patent discloses a stack of three lawn and garden spreaders packaged in a two part carton. During shipping such a carton is banded or taped to keep the two parts together. Upon delivery a retailer removes the band or cuts the tape, removes the upper part and displays the stacked products in the lower part.

There are problems, however, with the two part carton. If the lower part of the carton becomes wet, the part tends to deteriorate. The lower carton part also tends to be damaged when a loaded display is moved on rough concrete floors or when shoppers remove and then roughly replace stacked spreaders. Deteriorating and/or damaged cartons detract from the aesthetics of the product display, thereby adversely affecting sales. The two part carton also requires inserts to support the upper two spreaders. These added elements increase costs of the two part package and clutters the sales area as the top and middle spreaders are sold or removed and replaced by shoppers.

BRIEF SUMMARY OF THE INVENTION

The difficulties encountered with previous devices have been overcome by the present invention. What is described here is a packaging, shipping and display system including a first structure, a second structure, and a connector including a movable, pliable tab and an alignable opening, the tab being connected to either the first or the second structure and the opening being formed on the first or the second structure whichever is not connected to the tab.

A complete understanding of the present invention and other objects, advantages and features thereof will be gained from a consideration of the present specification which provides a written description of the invention, and of the manner and process of making and using the invention, set forth in such full, clear, concise, and exact terms as to enable any person skilled in the art to which it pertains, or with which it is most nearly connected, to make and use the same in compliance with Title 35 U.S.C. section 112 (first paragraph). Furthermore, the following description of a preferred embodiment of the invention read in conjunction with the accompanying drawing provided herein represent an example of the invention in compliance with Title 35 U.S.C. section 112 (first paragraph), but the invention itself is defined in the Claims section attached hereto.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 is a front isometric view of a packaging, shipping and display system of the present invention and includes a tray, a stack of products and a cover, with the cover being illustrated in phantom line.

FIG. 2 is a rear isometric view of the packaging, shipping and display system.

FIG. 3 is a front isometric view of a stack of trays.

FIG. 4 is a rear isometric view of a single tray.

FIG. 5 is a top plan view of the tray.

FIG. 6 is a sectional view taken along line 6-6 of FIG. 5.

FIG. 7 is a front elevation view of the tray.

FIG. 8 is a left side elevation view of the tray.

FIG. 9 is a sectional view taken along line 9-9 of FIG. 5.

FIG. 10 is a sectional view taken along line 10-10 of FIG. 5.

FIG. 11 is a bottom plan view of the tray.

FIG. 12 is a right side elevation view of the tray.

FIG. 13 is an enlarged view taken within circle 13-13 of FIG. 11.

FIG. 14 is an enlarged isometric view of a latching tab in a concave position.

FIG. 15 is an isometric view similar to FIG. 14 illustrating the latching tab in a convex position.

FIG. 16 is an upward looking, partially broken away, isometric view of the cover.

FIG. 17 is an isometric view of the cover and the tray.

FIG. 18 is an enlarged isometric view taken within circle 18-18 of FIG. 17.

FIG. 19 is an enlarged isometric view taken with the circle 19-19 of FIG. 17.

FIG. 20 is an isometric view of the packaging, shipping and display system being manually moved.

FIG. 21 is an isometric view of four packaging, shipping and display systems mounted on a pallet.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

While the present invention is open to various modifications and alternative constructions, the preferred embodiment illustrating the best mode contemplated by the inventors of carrying out their invention is shown in the various figures of the drawing and will be described herein in detail, pursuant to Title 35 U.S.C. section 112 (first paragraph). It is understood, however, that there is no intention to limit the invention to the particular embodiment, form or example which is disclosed herein. To the contrary, the intention is to cover all modifications, equivalent structures and methods, and alternative constructions falling within the spirit and scope of the invention as expressed in the appended Claims section attached hereto, pursuant to Title 35 U.S.C. section 112 (second paragraph).

Referring to FIGS. 1-2, there is illustrated a packaging, shipping and display system 10 including a first structure, such as a tray or base 12, and a second structure, such as a cover, shroud or sleeve 14. Stacked on the tray 12 are products to be shipped and displayed, such as three lawn and garden spreaders 16, 18, 20 of the type shown and described in U.S. Pat. No. 6,616,074 whose written description and drawings are incorporated here, in full, by reference.

Each of the lawn and garden spreaders, such as the spreader 16, may include a container or hopper 22 which is supported on a lower frame 24. The lower frame may be connected to an axle 26 and a pair of wheels 28, 30. Rotatably attached to the lower frame 24 is a tubular handle 32. The handle 32 is illustrated in a lowered or collapsed shipping position in FIGS. 1 and 2, and in an upright, operating position in FIGS. 1 and 2 of the above mentioned U.S. Pat. No. 6,616,074. Connected to the lower frame may be a rest stand 34.

During both shipping and display, the handles of the lawn and garden spreaders are in the collapsed position. As shown, the lowermost spreader 16 of the stack is mounted in the tray 12 and the two remaining spreaders 18, 20 are stacked in the hopper of the next lower spreader. During shipment and display, the packaged stack may include three spreaders although more or less spreaders, or other products, may be stacked as found to be convenient and consistent with the packaging material used, weight and volume limits and safety concerns.

It is noted that the cover 14 is illustrated in FIGS. 1 and 2 in phantom line so that the stacked spreaders 16, 18, 20 are visible. The actual cover is preferably formed of corrugated paper as more realistically illustrated in FIG. 17.

The tray 12 may be formed as a one piece molded plastic assembly. Along the border of the tray are slanted, upstanding, short outer walls including a front outer wall 40, FIGS. 3-12, a left side outer wall 42, a right side outer wall 44 and a rear outer wall 46. Adjacent to the outer walls are oppositely slanted inner walls 50, 52, 54, 56. The inner and outer walls form a peripheral recess 58. The slanted inner walls help locate the cover into the peripheral recess. The tray also includes a center portion that may include a central cutout 60, two rear cutouts 62, 64, two wheel wells 66, 68, a rear well 70 for a spreader rest stand, a central cutout border 65, a cutout rear wall 67 and a cutout front wall 69. The two wheel wells 66, 68 have rounded bottom surfaces 72, 74 and side retaining walls 76, 78. The rear well 70 includes a bottom wall 80, side walls 82, 84, a front wall 86 and a rear wall 88. The two wheel wells are positioned to receive the two wheels 28, 30 of the lowermost spreader 16 and the rear well 70 functions to receive the rest stand 34 of the same spreader 16. An obliquely positioned flap 90 is formed in the front wall 86 of the rear well 70, such that the combination of the wheel wells 66, 68, the rear well 70, the surrounding walls 76, 78, 82, 84, 86, 88 and the flap 90 locate the spreader and prevent the lowermost spreader 16, and thereby the stack of spreaders, from moving forwardly, rearwardly or laterally relative to the tray. There is a friction fit between the spreader and the rear well 70 with the flap 90. As long as the tray is kept reasonably level, the stack of spreaders are stable, even without the cover, and hence easily transported. The stack of spreaders are also very stable at the point of sale where the stack will appear as shown in FIGS. 1 and 2, but without the cover 14. An important advantage of the packaging, shipping and display system 10 is the ease by which the system converts from a shipping mode to a display mode. There is no need for any labor or time to separate the spreaders from the tray.

Eight upstanding alignment ribs, two front ribs 92, 94, four rear ribs 95, 96, 97, 98, a left side rib 100 and a right side rib 102, are located in the peripheral recess 58, extending between the outer walls and the inner walls. The ribs reinforce the tray and act to align the cover 14 by being received by slots formed in the cover as will be explained below. At each corner of the peripheral recess 58 are large drainage holes 104, 106, 108, 110. Small holes 112, 114 are located at the front and rear, respectively, of the peripheral recess 58. A top wall 116 surrounds the cutouts 60, 62, 64.

The system also includes a connector, one part of which is on the tray 12 and the other part of which is on the cover 14. The one part is a pliable tab and the other part is an opening as will be explained in detail below.

A pair of pliable latching or connector tabs 120, 122 may be formed at the rear of the tray along with a pair of latching cutouts 124, 126. A left side pliable latching tab 130 is located along the inner wall 52 of the tray formed in a cutout 132, and a right side pliable latching tab 134 is located along the inner wall 54 formed in a cutout 136. Each latching tab, such as the right latching tab 134, is formed of a strip of bendable material 150 connected to a corresponding inner wall, such as the inner wall 54, with a living hinge 152, 154, FIG. 11, at each end. The rear latching tabs 120, 122 include living hinges 160, 162 and 164, 166, and the left side tab 130 includes living hinges 168, 170. Each latching tab, such as the right latching tab 134, includes just inward of the living hinge 154, a thickened portion 172, FIG. 13, which tapers down to the center 174 of the strip. Each latching cutout, such as the cutout 134, includes a curved finger portion 176 so that a user may manipulate the tab to snap or pop the pliable latching tab from a concave configuration as shown in FIG. 14 to a convex configuration shown in FIG. 15. The latching cutout 124 includes finger portion 177, the latching cutout 126 includes finger cutout 178 and the latching cutoff 132 includes the finger portion 179.

The front slanted wall 50 projects upwardly and presents a surface for a name, trademark or logo. Reinforcing ribs, such as front reinforcing ribs 181, 182, rear reinforcing ribs 184, 186, left side reinforcing ribs 188, 190 and right side reinforcing ribs 192, 194 are formed on the underside of the tray as shown in FIG. 11. These ribs allow efficient stacking of the trays for warehousing and shipment without binding together.

The living hinges 152, 154, 160, 162, 164, 166, 168, 170 have a thickness of about 0.026 inches, a thickened portion of about 0.080 inches which tapers to about 0.045 at the center of the strip as shown in FIG. 13. The material and dimensions are designed to cause the latching tabs to be popped outwardly or pushed inwardly simply by using force from a user's finger alone and does not require any tools. Pushing invardly may also be accomplished with a shoe toe. The latching tabs are sufficiently strong to not shear or fatigue even when supporting the weight of three spreaders and the tray, about 50 pounds. The tray is about 23.875 inches wide and about 20.1 inches in depth. The slanted front wall 50 is about 3.940 inches high and the rear slanted wall 54 is about 4.074 inches high. The material of the tray may be polypropylene having a starting or nominal thickness of about 0.90 inches. The material may be Equistar 35 BU01PP which may be purchased from Talco Plastics of Long Beach, Calif. Other suitable material may also be used.

The cover 14 may have the shape of a prism with a front wall 200, FIGS. 16-18, a rear wall 202, a left side wall 204, a right side wall 206, a closed top 207 and an open bottom 208. The cover may be made of corrugated paper, plastic or any other suitable material. The open bottom of the cover includes a lower edge portion 210 with two tab receiving openings or connector cutouts 212, 214 in the rear wall 202, a tab receiving opening or connector cutout 216 in the left wall 204, and another tab receiving opening or connector cutout 218 in the right wall 208. Each tab receiving connector cutout is very generally configured as a rectangle, with a finger receiving openings 220, 222, 224, 226 being formed along the upper borders 230, 232, 234, 236 of the rectangles and similarly shaped projections 240, 242, 244, 246 extending upwardly from the lower borders 250, 252, 254, 256 of the rectangles.

The tab receiving cutouts of the cover 14 are part of a group of connectors that also include the latching tabs. It is to be understood, however, that the cutouts may be formed in the tray and the tabs may be located on the cover.

A pair of rib slots 260, 262 are formed in the front wall 200, another pair of rib slots 264, 266 are formed in the rear wall 202, a fifth rib slot 268 is formed in the left wall 204, and a sixth rib slot 270 is formed in the right wall 206. The six slots 260, 262, 264, 266, 268, 270 are aligned to receive the tray ribs 92, 94, 96, 98, 100, 102, respectively. A left side hand cutout 272, FIG. 16, and a right side hand cutout 274 may be formed in the left and right side walls 204, 206, respectively.

The lower edge portion 210 ofthe cover 14 is received by the peripheral recess 58 in the tray 12 and the rib slots 260, 262, 264, 266, 268, 270 are aligned with and received by the ribs 92, 94, 96, 98, 100, 102, located in the recess 58 when the tray 12 and the cover 14 are engaged. The four tab receiving cutouts 212, 214, 216, 218 are spaced to align with the latching tabs 120, 122, 130, 134 of the tray. In FIG. 17 the cover 14 is shown mounted to the tray 12 but the cover has not been fully locked or latched to the tray. For example, the latching tab 134, FIG. 18, is convex and locking; the latching tab 122, FIG. 19, is concave and not yet locking. In FIG. 20, the tabs are all shown in locking positions such that an interference or abutment has been created between a bottom edge of the latching tabs 120, 122, 130, 134 and the bottom border of the cover cutouts 212, 214, 216, 218. For example, this abutment is illustrated in FIG. 18 between the bottom edge 280 of the tab 134 and the bottom border 256 of the cutout 218.

The tab receiving cutouts 212, 214, 216, 218 are about 2.25 inches wide, about 1.75 inches high, plus another 1.75 inches for the finger receiving cutouts 220, 222, 224, 226, and the projections 240, 242, 246, 248 extend about 0.75 inches high. The latching tab strip is about 2.9 inches long, about 1.2 inches high and has a curved set back of about 0.725 inches in the unlocked position shown in FIGS. 11 and 13. The sides of the latching tabs are slightly oblique, curving upwardly at about a six degree angle.

In use, the trays 12 may be molded at a distant location, stacked on one another as shown in FIG. 3 and delivered to a factory where spreaders are assembled. The covers 14 may also be manufactured, cut and glued at another distant location and shipped in a flattened condition to the factory where the spreaders are assembled. As each spreader is fully assembled, it may be stacked on a tray generally three or four spreaders high as illustrated in FIGS. 1 and 2. A cover may then be placed over a stack of spreaders ensuring that the slots and cutouts of the cover are aligned with the ribs and latching tabs, respectively, of the tray. Thereafter, factory personnel place a finger into each of the cover finger receiving openings 220, 222, 224, 226 and into tray finger portion cutouts 176, 177, 178, 179 behind the latching tabs 120, 122, 130, 134 so as to manipulate the latching tabs outwardly in order to snap the latching tabs through the cutouts 212, 214, 216, 218. By pulling outwardly on each of the latching tabs, an interference or abutment fit is created between the tray latching tabs and the cover. Each of the packaged stacks of spreaders may then be placed on a pallet 282 as shown in FIG. 21. When four of such stacks 290, 292, 294, 296 are deposited, a forklift truck may be used to move the loaded pallet to a shipping dock for loading onto a truck. The manipulation of the latching tabs may be automated.

Once the pallet of packaged, stacked spreaders reaches a retailer, each stack may be unloaded and carried manually by an employee 284 to a display site, as shown in FIG. 20. At the display site, a store employee pushes the latching tabs inwardly with his/her thumb or the toe of a shoe. This action snaps the pliable latching tabs inwardly to a concave position and removes any interference between the cover and the tray. Thereafter, the cover may be lifted upwardly and separated from the tray. The tray and a stack of spreaders are then suitable for sales display. Furthermore, the stack may be easily moved along a floor by dragging the stack while on a tray. This allows the retailer to readjust the sales display as desired.

The tray and cover combination requires no tape, staples or straps nor is there a need for paper fillers. The combination is also lower in weight and is easily handled so that labor costs are reduced. The tray has a much longer shelf life than corrugated packaging and is weather resistant.

The above specification describes in detail a preferred embodiment of the present invention. Other examples, embodiments, modifications and variations will, under both the literal claim language and the doctrine of equivalents, come within the scope of the invention defined by the appended claims. For example, the exact shape and size of a tray and cover may vary to accommodate different sized products. Also, the form of the tray may vary as a function of the product to be stacked. Furthermore, the shapes and dimensions of the tabs and cutouts may be adjusted as a function of material used, product stacked and load to be carried. These are all considered equivalent structures and will also come within the literal language of the claims. Still other alternatives will also be equivalent as will many new technologies. There is no desire or intention here to limit in any way the application of the doctrine of equivalents nor to limit or restrict the scope of the invention. 

1. A packaging, shipping and display system comprising: a first structure; a second structure; and a connector including a movable, pliable tab and an alignable opening, said tab being connected to either said first member or said second member and said opening being formed on said first or second structure having an absence of said tab, said first structure and said second structure for supporting a stack of products and for covering said stack of products.
 2. The system of claim 1 wherein: said first structure is a base adapted to mount the stack of product; and said second structure is a cover mounted to said base and being connected thereto.
 3. The system of claim 2 wherein: said pliable tab is integral with said base; and said opening is formed in said cover.
 4. The system of claim 3 wherein: said base includes an upstanding rib; and said cover includes a vertically oriented slot for receiving said rib.
 5. The system of claim 3 wherein: said cover includes a lower edge portion; and said base includes a recess along a peripheral portion of said base, said recess for receiving said lower edge portion of said cover.
 6. The system of claim 5 wherein: said base includes an integral upstanding rib; and said cover includes a vertically oriented slot for receiving said rib.
 7. The system of claim 6 wherein: said base is shaped to correspond to a portion of the product to be stacked on said base.
 8. The system of claim 7 wherein: said base includes slanted side walls and ribs to facilitate stacking of a plurality of said bases.
 9. A packaging, shipping and display system for accommodating a stacked array of products comprising: a base structure for supporting the stacked array of products in a desired alignment, a cover structure for attachment to the base structure to provide a protective covering surrounding the stacked array of products supported by the base structure; said base structure including an integral pliable tab member; and said cover structure including an opening alignable with said pliable tab member for selectively receiving said pliable tab member to removably connect said base structure to said cover structure.
 10. The system of claim 1 wherein: said base is generally rectangular in shape and includes first and second integral pliable tabs located to the rear of said base and third and fourth integral pliable tabs, one each located on a side of said base.
 11. The system of claim 9 wherein: said base includes an integral upstanding rib; and said cover includes a vertically oriented slot for receiving said upstanding rib.
 12. The system of claim 9 wherein: said cover includes a lower edge portion; and said base includes a recess located along a peripheral portion of said base, said recess for receiving said lower edge portion of said cover.
 13. The system of claim 9 wherein: said base is formed with a shape corresponding to a portion of the product to be stacked on said base.
 14. The system of claim 9 wherein: said base includes holes located in a peripheral portion of said base.
 15. The system of claim 9 wherein: said base includes slanted side walls to facilitate stacking of a plurality of said bases.
 16. The system of claim 9 wherein: said base includes a raised and slanted front wall for displaying information.
 17. The system of claim 9 wherein: said base includes an integral upstanding rib; said cover includes a vertically oriented slot for receiving said upstanding rib; said cover includes a lower edge portion; and said base includes a recess along a peripheral portion of said base, said recess for receiving said lower edge of said cover.
 18. The system of claim 17 wherein: said supporting structure of said base has a shape corresponding to a portion of the product to be stacked on said base.
 19. The system of claim 18 wherein: said base includes drain holes located in said peripheral portion of said base.
 20. The system of claim 19 wherein: said base includes slanted side walls to facilitate stacking of a plurality of said bases. 